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Dane's Hybrid Conversion Thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by Dane, Apr 11, 2011.

  1. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 10, 2011]
    cost predominantly morgan.. although timescale is a factor currently

    I must admit I forgot about TSR one when I posted earlier.. the confidence comment is not appropriate for that one, it looks as good as you can get a fabricated one.

    TSR looks quality from the pictures

    only technical question I have on it is its bore size & longer runners vs spool... From the pictures it looks like 1.5" sch pipe. Is this the size ?

    PS. hope you are feeling better
    Last edited: May 10, 2011
  2. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 10, 2011]
    that log looks ok...
    not a "fill" question, just a cost one then...

    I know the work involved and its not tsr cahing in, its that labour intensive to make something like that as well as that. (whoever fabs it for tsr will be putting in many hours to make one) - its the design which makes it that labour intensive & costly.. which is why I am attempting to make a simpler version.. less parts, less welding, but hopefully functional. We will see of course. might all go tits up yet - lol
  3. Morgan-VAGCHECK
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    Morgan-VAGCHECK Foot to the floor

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    [May 10, 2011]
    Hi Welly,

    If you do find it then it would be most appreciated if you can point me too it, because if this was last year then the logs in theory can only have come from my own TT... & I don't remember posting any ! (That said my memory is ****e)

    I did post a log recently at Bills request here (this does show more lag, but it had a little less pre-load on the actuator than the example above) >

    The Audi TT Forum :: View topic - There is no end to mods.... 297.61BHP ACHIEVED

    Dane sorry for the small highjack, & I wish you all the best with your own hybrid build.

    Regards
    Morgan
    Last edited: May 10, 2011
  4. Dane
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    Dane Faster than a V12 Q7

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  5. Morgan-VAGCHECK
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    Morgan-VAGCHECK Foot to the floor

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    [May 10, 2011]
    Hi Bill,

    I am told the runners are 35mm.

    Unfortunately I am still suffering a bit after the op... I just can't sit still & rest to let everything heal (Get bored very quickly!) but thanks for asking :)

    Apologies again to Dane for taking his build thread slightly off topic !

    Regards
    Morgan
  6. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 10, 2011]
    Dont worry about it. Dane tends to de-rail everyone elses threads ;)
  7. Dane
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    Dane Faster than a V12 Q7

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    [May 10, 2011]
    :lmfao: Oi! I've been good lately.
  8. slappy_dunbar
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    slappy_dunbar Let's Do This

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    [May 10, 2011]
    Morgan --- the spool you are getting on that manifold is excellent. I would put that as the standard to beat for any combination of hybrid turbo / aftermarket manifold. Did you ever log up to and past redline on it? I'd be interested to see when (if?) the boost pressure drops back into the MAP sensor's range.
  9. Welly
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    Welly VX220 SC Driver :)

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    [May 10, 2011]
    Will do. I'll have a look later.
  10. Sandip
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    Sandip Well-Known Member

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    [May 10, 2011]
    Sorry to add to the drifting off topic Dane, here's a log of mine with the JBS manifold, i know they aren't available yet but you never know one day they might be.
    [​IMG]

    So is the main benefit of a higher flowing manifold so that the k04 can spool up a lot quicker??
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 10, 2011]
    high flow manifolds are there to support the flow.... and sustain it not choke it like oe one does.
    whether it spools faster? hmm dont know.

    Picture of TSR's mani for ref..
    [​IMG]
    fitted
    [​IMG]

    Mine is looking nothing like this - lol for good or bad
    Last edited: May 10, 2011
  12. Morgan-VAGCHECK
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    Morgan-VAGCHECK Foot to the floor

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    [May 10, 2011]

    Hi Slappy,

    Thanks for the comments.

    Spool is certainly not any real issue as you note.. however I am experiencing some very light surging. It’s not so bad pressure starts to fluctuate, but certainly flow can be a little unstable at lower rpm’s when stepping on the gas unless I limit the pressure to a level I find well... unexciting

    My own (hard) rev limiter is currently set at only 7100rpm although I will be raising this, so I have no logs higher than this currently.

    Below is an example from the same days testing nearly touching the rev limiter with actual pressure on top measured at ~1.65 bar on my external logger. (There was less pre-load on the actuator to the log above, but a little more N75 DC allowed)

    [​IMG]

    If anyone is wondering about the very high IAT's, these logs were more from an initial "endurance & is it going to work" mani testing session on TSR's dyno hence some long pulls at full load... IAT's do not get as hot as this in real world conditions.

    Regards
    Morgan
  13. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 10, 2011]
    you done much more on it since november last year?
    how would you sum it up if complete?
  14. slappy_dunbar
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    slappy_dunbar Let's Do This

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    [May 11, 2011]


    Freaking sensational. Never mind the IATs -- you're running nearly 30secs continuously on a dyno. I love the power delivery you're getting, especially if you factor in the quicker spool illustrated above. Wow.
  15. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 11, 2011]
    maybe 2283 based units are'nt all that bad eh doug? ;)
  16. Morgan-VAGCHECK
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    Morgan-VAGCHECK Foot to the floor

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    [May 11, 2011]
    Hi Bill,

    Mapping wise very little has been done.. mainly due to it taking a back seat to customers vehicles, but also plenty of little unrelated hardware issues to be resolved.. fix one thing & in a matter of days I find something else needing attention..

    Leaking core in a few months old Forge FMIC... coolant leak on OE oil cooler jacket, fuel pump headaches, trip to bodyshop thanks to some idiot etc

    The only real progress with the mapping is it is now calibrated for & using a 3bar MAP sensor, so I can keep boost control fully closed loop.

    If I had to sum it up... its been a royal pain in the ass !

    I would like to think "hopefully" & assuming no more bad luck, it will all be finalised around late June.. bearing in mind I can't currently work/drive/make any progress due to the op.

    Regards
    Morgan
  17. Welly
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    Welly VX220 SC Driver :)

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    [May 11, 2011]
    That sounds useful - planning on running N75 control?
  18. Dane
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    Dane Faster than a V12 Q7

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    [May 11, 2011]
    I'm going to pop over tonight if thats alright Bill?

    Also any word from Milltek?
  19. Speedy Steve
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    Speedy Steve Active Member

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    [May 11, 2011]
    we need teaser photos of the manifold. Dont let us down Dane!
  20. Morgan-VAGCHECK
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    Morgan-VAGCHECK Foot to the floor

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    [May 11, 2011]
    Hi Welly,

    My boost has always been controlled via the N75 with this hybrid... however previously in an "open loop" type manner.

    Regards
    Morgan
  21. Dane
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    Dane Faster than a V12 Q7

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  22. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    ps make sure your heat wrap goes around your Forge charge pipe kids

    [​IMG]

    melty melty
  23. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 12, 2011]
    Oh deah. I did notice you weren't running the heat wrap when I saw your car at Bills!

    Oh what's going on with the game of hangman in your signature? ;)
  24. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    I think I ripped it, and now it won't stay in place :ermm:

    My Sig is getting a letter every day until it says Badger 5 edition or I get my car back lol, It's a count down of sorts.
  25. Welly
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    Welly VX220 SC Driver :)

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    [May 12, 2011]
    Bloody hell. I didn't have heat wrap around mine and it came off fine.... Weird?
  26. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    It came off easy enough, it had just melted around the lip on the charge pipe over the mani, I haven't been driving it that hard... honest :ninja:
  27. Welly
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    Welly VX220 SC Driver :)

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    [May 12, 2011]
    What's that smell?? No, it's not burning Nomex, it's bull ****....
  28. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 12, 2011]
    No doubt it happened when I drove it! :whistle2:
  29. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    There we go, thats the reason, Westle broke something else on my car! Thrashing it around the roundabouts - me clinging on for dear life :)
  30. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 12, 2011]
    I cant remember what the first thing was I broke?

    I treated your car like a fine woman. I was soft and gentle and caressed her through the bends.

    :racer:
  31. Welly
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    Welly VX220 SC Driver :)

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    [May 12, 2011]
    That's not how I like to treat fine women.... :think:
  32. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Ok ok, I was hard and rough and slapped her about.
  33. Welly
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    Welly VX220 SC Driver :)

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    [May 12, 2011]
    Excellent, a good old pull on the hair normally goes down well too...
  34. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    :lmfao:

    he slapped me about and all! :slapped:

    I can't remember what the first thing was(n't)
  35. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    :lmfao:
  36. Dane
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    Dane Faster than a V12 Q7

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    [May 12, 2011]
    I appear to have de-railed my own thread lol
    Last edited: May 12, 2011
  37. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [May 12, 2011]
    :haha:
  38. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 12, 2011]
    just run out of argon dammit
  39. Dane
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    Dane Faster than a V12 Q7

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  40. badger5
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    [May 12, 2011]
    back with new bottle, on contract with air-products now. smaller bottle, higher pressure built in regulator.. bought another flow gauge also now so I will have full control of purge.. I have to say tho this mani is a proper PIA to make

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